U.S. patent application number 16/800028 was filed with the patent office on 2020-09-03 for biodegradable tea and coffee wrapper and tag.
This patent application is currently assigned to Nonwoven Network LLC. The applicant listed for this patent is Nonwoven Network LLC. Invention is credited to Stephen W. Foss.
Application Number | 20200277132 16/800028 |
Document ID | / |
Family ID | 1000004701551 |
Filed Date | 2020-09-03 |
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United States Patent
Application |
20200277132 |
Kind Code |
A1 |
Foss; Stephen W. |
September 3, 2020 |
Biodegradable Tea and Coffee Wrapper and Tag
Abstract
A tea and coffee bag wrapper and tag is shown with improved
properties than current state of the art wrappers and tags. The
novel tea bag and coffee bag tags and wrappers are non-GMO and
fully compostable in about 30 days. Unlike other tags and wrappers
that can remain in a compost for years, the present tags and
wrappers completely biodegrade within 30 days. In one aspect, a PLA
mono-component fiber is utilized at a specific blend ratio of L and
D PLA structure. The manufacture of the same is also disclosed.
Inventors: |
Foss; Stephen W.; (Naples,
FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nonwoven Network LLC |
Naples |
FL |
US |
|
|
Assignee: |
Nonwoven Network LLC
Naples
FL
|
Family ID: |
1000004701551 |
Appl. No.: |
16/800028 |
Filed: |
February 25, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62813094 |
Mar 3, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04H 5/04 20130101; B65D
85/8085 20130101; D10B 2401/12 20130101; D10B 2505/10 20130101;
D10B 2331/041 20130101; B65D 65/466 20130101 |
International
Class: |
B65D 85/808 20060101
B65D085/808; B65D 65/46 20060101 B65D065/46; D04H 5/04 20060101
D04H005/04 |
Claims
1. A non-woven fabric composition web for a tea or a coffee wrapper
and tag consisting of: a tea or a coffee wrapper and tag having a
plurality of mono-component, mono-constituent polylactic acid (PLA)
fibers and a pigment; the polylactic acid (PLA) fibers having
different deniers and a blend percentages of a high melt PLA fiber
and a low melt PLA fiber having a melt flow temperature in a range
of 145-175.degree. C. and 105-165.degree. C., respectively; and
wherein, the tea or the coffee wrapper and tag are non-GMO and
fully compostable in about 30 days.
2. The non-woven fabric composition in claim 1, wherein the fibers
have a weight range from 55 gsm to 150 gsm.
3. The non-woven fabric composition in claim 1, wherein the fibers
have a weight range from 55 to 75 gsm.
4. The non-woven fabric composition in claim 1, wherein the fibers
have a percentage of a high melt fiber ranging from 55% to 95%, and
a percentage of a low-melt fiber ranging from 5% to 45%.
5. The non-woven fabric composition in claim 1, wherein the fibers
have a denier ranging from 0.7 to 6.0 denier.
6. The non-woven fabric composition in claim 1, wherein the fibers
have a length that ranges from 12 mm to 130 mm.
7. The non-woven fabric composition in claim 1, wherein the fibers
have a denier ranging from 1.5 to 2.5 denier.
8. The non-woven fabric composition in claim 1, wherein the fibers
have a length that ranges from 25 mm to 51 mm.
9. The non-woven fabric composition in claim 1, wherein the pigment
is a titanium dioxide pigment for making the non-woven fabric
composition opaque in color.
10. The non-woven fabric composition in claim 1, wherein the
pigment is a color fast pigment selected from a group consisting of
Phthalo Blue, Phthalo Green, iron oxide, Yellow Ochre, and any
combination thereof, and wherein the pigment is combined with
either the low melt PLA fiber, the high melt PLA fiber, or both the
low and the high melt PLA fibers to provide a colored fabric.
11. The non-woven fabric composition in claim 1, wherein the tea or
the coffee wrapper and tag are printable with text, drawings, or
logos in biodegradable colored ink.
12. The non-woven fabric composition in claim 1, wherein the
composition for the tea or the coffee wrapper and tag is used for
wrapping meat, vegetables, fish, candy, cheese, or foodstuff to
provide controlled breathability and rapid biodegradability.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. provisional
application No. 62/813,094 filed Mar. 3, 2019, the disclosure of
which is hereby incorporated herein by reference.
FIELD OF USE
[0002] The present disclosure relates to a biodegradable beverage
wrapper and tag, and more particularly to the manufacture of a tea
coffee bag tag and related wrappers that is non-GMO and fully
compostable.
BACKGROUND OF THE INVENTION
[0003] With the proliferation of biodegradable and recycled
materials, there is a need for a substrate, particularly for tea
and coffee wrappers and tags, which provides for 100%
bio-degradable and does not contain any inert or non-biodegradable
components.
[0004] The tea hag was invented by accident more than 1.00 years
ago by an American merchant Thomas Sullivan, who decided to send
samples of tea to customers in small silk pouches. Some people were
confused--assuming that the bags were supposed to be dunked in hot
water just like traditional metal tea infusers. When Sullivan heard
what they were doing, he spotted a gap in the market. Thus,
serendipitously, the tea bag was born.
[0005] At first, there were complaints that the mesh of the bags
was too fine, so he replaced the silk with gauze. And as tea bags
entered mass production, cheaper paper was used instead. Tea
drinkers were reluctant to abandon loose leaf tea, but by the
1950s, when families were embracing new labor-saving gadgets like
never before, tea bags took off.
[0006] Bill Gorman, of the UK Tea Council, credits the tea bag with
saving the tea industry. "We would not be drinking the volume of
tea we do now without them,` he says--and he would know. "The UK is
the second-largest tea market per person in the world. Ireland is
first. Without tea bags, the industry would be on its knees."
[0007] Major brands such as PG Tips and Tetley no longer use wood
pulp to make their paper, but a vegetable fibre derived from the
abaca plant--a relative of the banana grown mostly in Indonesia and
South America. However, according to the Tea Council, tea companies
certainly use a lot of it --, around 96 percent of the tea made is
with tea bags.
[0008] It adds up to a lot of paper, particularly when so many tea
bags are no longer rectangular--the least wasteful design for a tea
hag--but round or pyramid-shaped. A PG Tips pyramid bag, for
instance, is made from a rectangle of perforated filter paper
approximately 70 cm square. A traditional square tea bag, on the
other hand, uses around 50 cm square of paper.
[0009] It is estimated that tea drinkers in Britain alone throw out
370,000 tons of tea bags and tea leaves each year, along with
vegetable peelings, onion skins and coffee grinds. Most of this
ends up in landfill sites. The environmental impact of tea bags
could easily he reduced if people simply threw the bags on the
compost heap or flower beds. But it's not that simple. For while
most of a tea bag is made from biodegradable paper, around 2.0 to
30 percent is not made of biodegradable material.
[0010] In order to stop tea bags bursting open in transit or in the
cup, many are sealed with a strip of heat-resistant polypropylene
plastic. That plastic doesn't compost, even after a few years, and
gardeners often find these small plastic meshes amid their homemade
compost (along with those non-biodegradable stickers that are found
on fresh fruit such as apples). In addition wrappers and tags of
the tea don't readily biodegrade.
[0011] There have been attempts to solve this issue that has been
met with limited success. U.S. Pat. No. 8,828,895 describes a
method of making filter fabrics by utilizing mono-component,
mono-constituent fibers made from both high and low melt
temperature Polylactic Acid (PLA) fibers. U.S. Pat. No. 9,998,205
describes the use of mono-component PLA fibers combined with PLA
powders also have the ability to remove chlorine from drinking
water. Both patents describe string made from mono-component,
mono-constituent PLA fibers.
[0012] But, there appear to be no tags or wrappers that are non-GMO
and biodegradable in normal composting, and made from a renewable
resource. Most wrappers are made from plastic film or foils that
are made plastics or metals.
[0013] Thus, there remains a need in the art for a process and
material for coffee and tea wrappers and tags to completely
biodegrade.
SUMMARY
[0014] Compared to the above methods the present disclosure
fulfills the above criteria and provides additional benefits that
state of the art systems cannot provide.
[0015] The current apparatus and method provides for a polylactic
acid (PLA) that is a polymer that acts very much like polyester
(PET) but is biodegradable thermoplastic aliphatic polyester and is
made from renewable resources, such as corn starch, beets, and
sugar cane. Most producers use Genetically Modified Organism (GMO)
in the crops such as corn, beets, and the like as the feed stock
for PLA.
[0016] Total-Corbion uses sugar cane from Thailand that is required
to be non-GMO. The sugar cane is converted into sugar that can be
fermented to form PLA. PLA can be produced in both a L or D
configuration. The L form has a higher melt point. By combining the
D & L forms during polymerization, the melting point can be
lowered and controlled at a specified melt temperature.
[0017] Polymerization of a racemic mixture of L- and D-lactides
usually leads to the synthesis of poly-DL-lactide (PDLLA), which is
amorphous. Use of stereospecific catalysts can lead to heterotactic
PLA which has been found to show crystallinity. The degree of
crystallinity, and hence many important properties, is largely
controlled by the ratio of D to L enantiomers used, and to a lesser
extent on the type of catalyst used. Apart from lactic acid and
lactide, lactic acid O-carboxyanhydride ("lac-OCA"), a
five-membered cyclic compound has been used academically as well.
This compound is more reactive than lactide, because its
polymerization is driven by the loss of one equivalent of carbon
dioxide per equivalent of lactic acid.
[0018] Due to the chiral nature of lactic acid, several distinct
forms of polylactide exist: poly-L-lactide (PLLA) is the product
resulting from polymerization of L,L-lactide (also known as
L-lactide).
[0019] It is well know that PLA polymers range from amorphous
glassy polymer to semi-crystalline and highly crystalline polymer
with a known glass transition 60-65.degree. C., a melting
temperature 130-180.degree. C., and a tensile modulus 2.7-16 GPa.
Heat-resistant PLA can withstand temperatures of 110.degree. C. The
basic known mechanical properties of PLA are between those of
polystyrene and PET. It is also known that the melting temperature
of PLLA can be increased by 40-50.degree. C. and its heat
deflection temperature can be increased from approximately
60.degree. C. to up to 190.degree. C. by physically blending the
polymer with PDLA (poly-D-lactide). PDLA and PLLA form a highly
regular stereocomplex with increased crystallinity. The temperature
stability is maximized when a 1:1 blend is used, but even at lower
concentrations of 3-10% of PDLA, there is still a substantial
improvement. In the later case, PDLA acts as a nucleating agent,
thereby increasing the crystallization rate. Biodegradation of PDLA
is slower than for PLA due to the higher crystallinity of PDLA. The
flexural modulus of PLA is higher than polystyrene and PLA has good
heat sealability.
[0020] In one aspect, a non-woven fabric composition web of
mono-component, mono-constituent PLA fiber composition consisting
of: a mono-component, mono-constituent polylactic acid (PLA) fiber.
The polylactic acid (PLA) fiber has different deniers and blend
percentages of high and low melt fibers. The fibers, in one
embodiment, have a melt flow temperature in a range of
145-175.degree. C. and 105-165.degree. C., for high melt flow
fibers and low melt flow fibers respectively.
[0021] Any combination and/or permutation of the embodiments is
envisioned. Other objects and features will become apparent from
the following detailed description considered in conjunction with
the accompanying drawings.
[0022] It is to be understood, however, that the drawings are
designed as an illustration only and not as a definition of the
limits of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The patent or application file contains at least one drawing
executed in color. Copies of this patent or patent application
publication with color drawing(s) will be provided by the Office
upon request and payment of the necessary fee.
[0024] To assist those of skill in the art in making and using the
disclosed composition and method, reference is made to the
accompanying figures, wherein:
[0025] FIG. 1 shows a photomicrograph of the material used for a
beverage tag and wrapper in accordance with one embodiment of the
present disclosure;
[0026] FIGS. 2A-2B illustrate the front and back, respectively, of
one embodiment of a wrapper, and illustrating that color design may
be utilized.
DETAILED DESCRIPTION
[0027] U.S. Pat. No. 8,828,895 describes methods to select a
percentage of high temperature PLA blended with a low temperature
PLA. The present invention is unlike bi-component fibers that have
a specific percentage of high temperature polymer in a core and
percentage of low temperature polymer on a sheath. This arrangement
limits the ability to provide an intimate blend of fibers that can
be adjusted for specific physical properties.
[0028] By using mono-component, mono-constituent fibers, the
diameter, length, fiber shape, and melt temperature can be adjusted
to achieve that desired properties. The low melt fiber melts
completely and flows and adheres to the high melt fibers as shown
in for example in FIG. 1. As shown, reference number 101 shows a
PLA or Co-PLA fiber with a low melting point at about 130 C. In
this embodiment, the fiber is shown after calendaring. Reference
number 102 shows a PLA fiber in the same composition with a high
melting point at about 175 C. Note that these different melting
points are not a core fiber and a surrounding sheath fiber as
previously known in the art.
[0029] While the US patent U.S. Pat. No. 8,828,895 provided for
media up to 55 grams/square meter (gsm), tags and wrapping require
heavier weights to obtain the strength and stiffness required. Thus
this patent is not useful for tags or wrappers.
[0030] It was found in the present invention that by regulating the
percentage of low melt fibers and processing conditions, the
various properties of thickness, porosity, tensile strength and
elongation can be controlled.
[0031] The following Examples further describe this material and
process. The below examples are given merely to show how the
invention may be implemented and in no way limits the invention to
any particular embodiment.
Example 1
[0032] Initial production was produced with the following
blend:
[0033] 85% PS2438 1.5d.times.2.0'' High Melt--170-175.degree. C.
Melt Point
[0034] 15% PS 2971 2.5d.times.1.5'' Low Melt--130.degree. C. Melt
point
[0035] The production line had 3 carding machines 2.5 m wide
equipped with randomizer rolls to orient the fiber approximately
2:1 machine direction: cross-machine direction.
[0036] The webs were deposited on a continuous apron and the web
was fed into a two-roll calendar heated at 140 C producing a
nonwoven fabric in widths up to 2.5 meter wide. Other lines are
capable of producing up to 5.5 m wide.
[0037] The product was produced at 40 gsm. While, this was
acceptable for coffee or dusty product pouches, it did not have
adequate strength and porosity needed for tags or wrapping.
Example 2
[0038] The next production run utilized a shorter Low melt fiber
with the hope of achieving better dispersion.
[0039] 85% PS2438 1.5d.times.2.0'' High Melt--170-175.degree. C.
Melt Point
[0040] 15% PS 2971 2.5d.times.1.0'' Low Melt--130.degree. C. Melt
point
[0041] The product was run on the same production line at 40 gsm.
The result was far better dispersion of the low melt fiber, but a
marginal improvement of physical properties.
Example 3
[0042] At this point, a change of fiber manufacturing line was
chosen to make more uniform fibers with less shrinkage to improve
web quality and faster production rates.
[0043] The fiber blend was also changed to achieve a stronger and
stiffer web. The new blend was:
[0044] 80% NwN Type 490 1.7 dTex (1.5 denier) PLA.times.50 mm (2'')
(Melt point 170.degree. C.)
[0045] 20% NwN Type 460 2.5 dTex (2.25 denier) PLA.times.38 mm
(1.5'') (Melt point 135.degree. C.)
[0046] The product was run at 40 gsm, but the strength increased by
80% and the stiffness was much improved.
Example 4
[0047] The next production run was established at an increased
weight of 60 gsm and an increased binder level:
[0048] 77% NwN Type 490 1.7 dTex (1.5 denier) PLA.times.50 mm (2'')
(Melt point 170.degree. C.)
[0049] 23% NwN Type 460 2.5 dTex (2.25 denier) PLA.times.38 mm
(1.5'') (Melt point 135.degree. C.)
[0050] The result was a very strong product at 60 gsm that was
suitable for printing and slitting for tags and wrappers.
[0051] The product was slit at 255 gsm and was printed at an
established label company. Logos were developed and printed on the
60 gsm product as shown in FIG. 2A and FIG. 2B. Also illustrated in
FIGS. 2A-B is the ability for the biodegradable material to be
printed in color. Biodegradable inks may be utilized to further the
biodegradability of the wrappers and tags. Printability on the
biodegradable formulation was shown to hold fine detail and color
images unlike other biodegradable mixtures in the past.
[0052] In one aspect, when the tags are made of the same components
as the filter media and string described in U.S. Pat. No.
8,828,895, all three products (filter, string, and tag) can be
attached to each other using ultra-sonic sealing at very high
speeds.
[0053] It was determined that a fabric with a weight greater than
50 gsm was superior for stiffness, tensile strength, and opacity.
The best weight range is from 55 to 120 gsm.
[0054] The wrapper material is 60 gsm and can be printed with
normal printing equipment and slit to the desired width. It seals
easily with both controlled heated platens or with ultrasonics.
[0055] Trials were performed on a pilot basis to increase the
percentage of low melt, mono-component, mono-constituent fibers.
The result was increased stiffness, increased strength and less
opacity. This appears to be helpful to improve the clarity of the
tea and coffee bags.
[0056] Fibers that are finer denier such as 0.6 to 1.4 denier will
allow for greater opacity and better coverage, but may sacrifice
strength. Fibers that are coarser such as 3 to 6 denier may be
stronger but may result is more holes and less coverage.
[0057] Further, increasing the binder content appears to decrease
the airflow and may allow the production of wrapping material with
controlled airflow to prevent the intrusion of undesirable
materials such as mold, mildew, fungus or bacteria through the
wrapping into the material inside the wrapping.
[0058] Further, this increased binder level can be adjusted to
allow moisture to escape from the material inside the wrapper.
[0059] Depending on the embodiment, the wrapper may be used for
meat, vegetables, fish, candy, cheese, or any foodstuff where
controlled breathability, printability, and rapid biodegradability
are desirable.
[0060] The tag and wrapper go completely clear when wet allowing
the material inside to be seen clearly. Since the wrapper can be
sealed with heat or ultrasonics, this eliminates the need for
sealing tape.
[0061] Additionally, Titanium Dioxide may be added to the fibers to
increase opacity. Other pigments such as Phthalo Blue, Phthalo
green, yellow ochre, iron oxide, or other color fast pigments may
be used to have colors that are water fast and withstand fading in
sunlight.
[0062] The printing could use vegetable dyes or the fabric could be
fully colored with vegetable dyes to remain organic and completely
compostable.
[0063] Finally, an impermeable film of PLA or other plastic such as
PE, PP, PET, or polyamide can be laminated to the wrapping to
prevent airflow in either direction of the wrapping material.
[0064] The following aspects were found possible utilizing the
teachings of the invention. A non-woven fabric composition web for
a tea or a coffee wrapper and tag consists of a tea or a coffee
wrapper and tag having a plurality of mono-component,
mono-constituent polylactic acid (PLA) fibers and a pigment. The
polylactic acid (PLA) fibers as described herein have different
deniers and a blend percentages of a high melt PLA fiber and a low
melt PLA fibers with a melt flow temperature in a range of
145-175.degree. C. and 105-165.degree. C., respectively. Again, the
tea or the coffee wrapper and tag are non-GMO and fully compostable
in about 30 days. In one aspect, the fibers have a weight range
from 55 gsm to 150 gsm. In another aspect, the fibers have a weight
range from 55 to 75 gsm. The fibers have a percentage of a high
melt fiber ranging from 55% to 95% and a percentage of a low-melt
fiber ranging from 5% to 45%. Depending on the embodiment, the
fibers may also have a denier ranging from 0.7 to 6.0 denier. The
fibers may also have a length that ranges from 12 mm to 130 mm
Fiber denier ranges from 1.5 to 2.5 denier as also achievable using
the principles of the present invention. The fibers may also have a
length that ranges from 25 mm to 51 mm Depending on the embodiment,
the pigment used with the fibers is a titanium dioxide pigment for
making the non-woven fabric composition opaque in color. The
pigment may also be a color fast pigment selected from a group
consisting of Phthalo Blue, Phthalo Green, iron oxide, Yellow
Ochre, and any combination thereof. Depending on the embodiment,
the pigment is added to either the low melt PLA fiber, the high
melt PLA fiber, or both the low and the high melt PLA fibers to
provide a colored fabric. The tea or the coffee wrapper and tag are
printable with text, drawings, or logos in biodegradable colored
ink or other ink that bio grades well. The wettability for the
material used for the tea and coffee wrappers and tags is
sufficient so that fine designs on the wrapper and tag do not bleed
off and keep their detailed form and color. The composition for the
tea or the coffee wrapper and tag may also be used for wrapping
meat, vegetables, fish, candy, cheese, or foodstuff to provide
controlled breathability and rapid biodegradability.
[0065] Any headings and sub-headings utilized in this description
are not meant to limit the embodiments described thereunder.
Features of various embodiments described herein may be utilized
with other embodiments even if not described under a specific
heading for that embodiment.
[0066] Although the invention herein has been described with
reference to particular embodiments, it is to be understood that
these embodiments are merely illustrative of the principles and
applications of the present invention. It is therefore to be
understood that numerous modifications may be made to the
illustrative embodiments and that other arrangements may be devised
without departing from the spirit and scope of the present
invention as defined by the appended claims.
[0067] While exemplary embodiments have been described herein, it
is expressly noted that these embodiments should not be construed
as limiting, but rather that additions and modifications to what is
expressly described herein also are included within the scope of
the invention. Moreover, it is to be understood that the features
of the various embodiments described herein are not mutually
exclusive and can exist in various combinations and permutations,
even if such combinations or permutations are not made express
herein, without departing from the spirit and scope of the
invention.
* * * * *